Coupling construction and method and apparatus for making the same

ABSTRACT

A pair of electrically conductive metallic sheath members respectively have ends disposed adjacent and spaced from each other in aligned relation with a metallic coupling sleeve disposed in telescoping relation about the adjacent ends of the sheath members. A pair of annular metallic shims are respectively deformed into substantially sealing engagement with and between a respective sheath member end and the sleeve to substantially close the spacing between the sleeve and the respective sheath ends whereby weld material subsequently utilized for securing the deformed shims respectively to the coupling sleeve and the sheath members at the exterior thereof does not cause contamination in the interior of the coupling sleeve and sheath members to adversely affect the high voltage conductor passing therethrough.

Umted States Patent 1191 1111 3,778,534 Jenkins Dec. 11, 1973 [5COUPLING CONSTRUCTION AND 2,647,769 8/1953 Smith 285/286 x METHOD ANDAPPARATUS FOR MAKING 3,406,986 10/1968 Jennings 285/21 THE SAME WilliamB. Jenkins, Henrico County, Va.

Reynolds Metals Company, Richmond, Va.

Filed: Sept. 29, 1971 App1.No.: 184,726

Inventor:

Assignee:

References Cited UNITED STATES PATENTS 11/1909 Hinds 174/84 SU 10/1953Mildner et a1. 174/88 C 111940 Kaysing 174/84 SU 10/1944 Bruno 285/286Primary Examiner-Darrell L. Clay Attorney-Glenn, Palmer, Lyne, Gibbs &Thompson [57] ABSTRACT A pair of electrically conductive metallic sheathmembers respectively have ends disposed adjacent and spaced from eachother in aligned relation with a metallic coupling sleeve disposed intelescoping relation about the adjacent ends of the sheath members. Apair of annular metallic shims are respectively deformed intosubstantially sealing engagement with and between a respective sheathmember end and the sleeve to substantially close the spacing between thesleeve and the respective sheath ends whereby weld material subsequentlyutilized for securing the deformed shims respectively to the couplingsleeve and the sheath members at the exterior thereof does not causecontamination in the interior of the coupling sleeve and sheath membersto adversely affect the high voltage conductor passing therethrough.

6 Claims, 9 Drawing Figures PAIENIEDHH: n 1925 F l 9 INVENTOR.

WILLIAM B. JENKINS BY ZYQ QQZM, KT Mom) FIG? HIS ATTORNEYS v COUPLINGCONSTRUCTION AND MET-HOD'AND APPARATUS FOR MAKING THE SAME BACKGROUND OFTHE INVENTION When a coupling is being made in the high voltageconductor means of a transmission line to provide an expansion jointtherein, a subsequent coupling must be made between the outersurrounding sheath members which have adjacent ends thereof disposedspaced from each other in order to cover the expansion joint coupling ofthe high voltage conductor.

In the past, a coupling sheath sleeve has been telescoped about one ofthe sheath members and is moved into telescoping relation over theadjacent ends of the conductive spacerbetween the high voltage conductorand the respective other sheath memberor at some other point inside theconduit arrangement in such a manner that such contamination might causearcing from the high voltage member to the outer sheath members andthereby disintegrate the'hig'h voltage conductor linea'nd/or form holesin the'outer sheath members. In addition, such arcing can 'besubsequently caused by the actual splatterof weld'material enteringbeneath the coupling member during the aforementioned welding operation.

SUMMARY This invention provides an improved coupling construction andmethod and apparatus for making such a coupling construction tosubstantially eliminate the aforementioned adverse weld contaminationproblem when coupling outer sheathmembers about a high voltageconductor.

One embodiment of the coupling construction of this invention comprisesa pairof annular-deformable metallic shims respectively disposed betweenthe adjacent spaced ends of the outer metallic sheath members and anouter telescoping metallic coupling sleeve bridging the gap between theadjacent-ends of thesheath-members. The deformable annular shims arerespectively deformed into substantially sealing engagement with andbetween the respective sheath'member ends and the coupling sleevetosubstantially seal close the spacing between the sleeve and therespective'sheath ends whereby a subsequent welding operation to securethe deformed shims respectively to thecoupling sleeve and the outersurface of the sheath member can take place without having any of thewelding material or contamination therefrom seeping into the interior ofthe coupling sleeve and sheath members'as in the;past.

Other details,-uses-and advantages of 'theinvention will'become apparentas the following descriptionof the present preferred embodiments thereofin the accompanying drawings proceeds.

DESCRIPTION OF THE DRAWINGS The accompanying drawings show the presentpreferred embodiment of the invention, in which:

FIG. 1 isa fragmentary, perspective view of the improved couplingconstruction of this invention.

FIG. 2 is a view to FIG. 1 with certain parts of the couplingconstruction broken away.

FIG. 3 is a view similar to FIG. 1 before the coupling construction hasbeen completed.

FIG. 4 is an enlarged, fragmentary, axial, crosssectional view of thecoupling construction of this invention prior to the deforming operationon the annular shims thereof.

FIG. 5 is a view similar to FIG. 4 and illustrates the couplingconstruction in its completed form.

.FIG. 6 is a front view of one of the annular shim members of thisinvention.

FIG. 7 is a side view of the shim of FIG. 6.

FIG. 8 is a fragmentary perspective view of one of the apparatus membersof this invention for deforming a shim of the coupling construction.

FIG. 9 is a view similar to FIG. 5 and illustrates another couplingconstruction of this invention.

DESCRIPTION OF ILLUSTRATED EMBODIMENT tallic, cylindrical conductor 11supported in spaced relation in an outer cylindrical metallic sheatharrangement '12 by a plurality of non-conductive spacers 13 insubstantially a conventional manner. However, at various points alongthe length of the inner connector 11, coupling constructions, such asexpansion joints 14, FIG. 2, are formed-between adjacent ends 15 and 16of adjacent conductor members 17 and 18 in a conventional manner. Suchinner coupling constructions 14 for the inner conductor 11 are usuallycovered by outer coupling constructions in the sheath arrangement 12.

The outer coupling construction 10 of this invention can be formedadjacent the internal coupling construction 14, but can also be formedanywhere along the transmission line as desired and comprises an outercylindrical metalliccoupling sleeve 19 disposed in telescoping relationover adjacent ends 20 and 21 of a pair of metallic sheath members 22 and23 disposed in spaced and aligned relation as illustrated in FIGS. 2, 4and 5, with deformable annular shims 24 of this invention respectivelydeformed in sealing engagement with and between an adjacent sheath end20 or 21 and the outer coupling sleeve 19 to substantially seal thespace therebetween. Such shims 24 are secured in suchdeformed'relationship as illustrated in FIG. 5 by annular weld material25 being disposed around each shim 24 to secure'that shim 24 not only tothe respective sheath member22 or 23 on the outer surface thereof, butalso posed in sliding contact with each other as illustrated in FIGS. 6and 7. In addition, the cylindrical ring 26 is subsequently bevelled onthe outer surface thereof to define an angular peripheral surface 29 asillustrated in FIG. 4 to be disposed in sliding and wedging relationwith an internal angular surface 30 cut at each end of the couplingsleeve 19 and angularly joining the internal cylindrical surface 31thereof as illustrated. If desired, the angular surfaces 30 of thesleeve '19 can extend to the outer cylindrical surface 32 thereof or beshort to define flat end surfaces 33 at each end of the coupling sleeve19 as illustrated in FIG. 4.

If desired, the internal peripheral surface 31 of the sleeve 19 can beprovided with annular or notched relief areas 34 that may be necessaryon set up when minimum spacing between the sheath members 22 and 23 isencountered.

The method of making the coupling construction of this invention willnow be described.

' As illustrated in FIG. 3, the annular shims 24 and coupling sleeve 19are disposed in telescoping relation on one of the sheath members 22 or23 that are disposed in spaced relation to provide a gap or spacing 35between the adjacent ends and 21 thereof to permit the inner couplingconstruction 14 on the conductor 11 to be completed. Thereafter, asillustrated, the righthand shim 24 is telescoped across the gap 35 ontothe right-hand sheath member 23 and the coupling sleeve 19 is moved tothe right in FIG. 3 to bridge the gap 35 and be in telescoping relationover the adjacent ends 20 and 21 of the sheath members 22 and 23. Atthis time, the left-hand and right-hand shim members 24 are moved intothe spacing between the respective adjacent ends 20 and 21 of the sheathmembers 22 and 23 and the coupling sleeve 19 as illustrated in FIG. 4.Thereafter, the apparatus 36 of this invention can be utilized to deformthe shims 24 into sealing engagement with the respective sheath ends 20and 21 and the outer sleeve 19 in the manner illustrated in FIG. 5 tosubstantially seal the spacing between the coupling sleeve 19 and thesheath members 22 and 23 for the reasons previously set forth.

For example, the apparatus 36 of this invention includes two annularmembers 37 constructed in a split manner so as to be adapted to bedisposed respectively in telescoping relation about the sheath members22 and 23 outboard of the coupling sleeve 19 and thereafter besimultaneously drawn inwardly toward the coupling sleeve 19 asillustrated by the arrows in FIG. 4 by suitable connecting arm means 38drawn together by any suitable electrical, mechanical, pneumatic,hydraulic or other force applying means to substantially uniformlydeform the shims 24 inwardly toward each other and through the wedgingrelation thereof with the sleeve 19 to inwardly and outwardly deform atthe ID and OD thereof respectively into sealing engagement with thesheath members 22 and 23 and the coupling sleeve 19 to seal the spacingtherebetween. Thus, during a subsequent welding operation to provide theannular weld material for securing the shims 24 in place, weldcontamination cannot enter the coupling sleeve 19 and produce theaforementioned adverse effects on the high voltage conductor 11.

In order to initially secure the deformed shims 24 in their previouslydescribed deformed relationships with the sleeve 19 and the sheathmembers 22 and 23 before the annular weld 25 is formed, each annularmember 37 of the apparatus 36 has a plurality of outwardly directedtongues 39 extending from the body portion 40 thereof and disposed flushwith the inner cylindrical surface 41 thereof to define a plurality ofspacings 42 therebetween and through which suitable spot weldingequipment can be utilized to spot weld the shims 24 to the respectivesheath member 22 or 23 while the annular members 37 are holding theshims 24 in their deformed relationship as illustrated in FIG. 5.Thereafter, once the shims 24 have been spot welded in place, theannular members 37 of the apparatus 36 can be backed off of the shimmembers 24 and conventional welding apparatus can be utilized to formthe annular welds 25 about the shims 24 to secure the same respectivelyto the sheath members 22 and 23 and to the end surfaces 33 of thecoupling sleeve 19 as illustrated.

While only one embodiment of this invention has now been described, itis to be understood that variations therein can be made while stillperforming the desired coupling function of this invention as previouslydescribed.

For example, while the shims 24 are angularly split to define theangular surfaces or ends 27 and 28 thereof, such shims 24 could beformed of solid material, such as by extrusion, etc., to be merelydeformed inwardly and outwardly through the wedging relationship thereofwith the surfaces 30 of the sleeve 19. Alternately, a split arrangementin the shim 24 could be provided by other configurations, such as atongue and groove arrangement, an overlapping of flat surfaces, etc.,the important feature being that the annular shim 24 of this inventioncan be readily deformable from the original configuration thereof bothinwardly and outwardly thereof to substantially seal against the innersheath member and the outer coupling sleeve for the reasons previouslydescribed.

It has been found that such deforming of the annular shims 24 of thisinvention actually causes the sheath member ends 20 and 21 to bedeformed into concentric relation with the shims 24 for intimate sealingcontact therebetween when such sheath ends 20 and 21 are not truelycylindrical, as is normally the case.

In addition, while additional weld material 25 has been previouslydescribed for securing the shims 24 in place, such as being formed fromsuitable filler material from a gas metal arc welding operation, it isto be understood that a tungsten inert gas welding operation can beutilized where the shim member 24 itself forms the weld material betweenthe shim member 24 and the sheath member and the outer coupling sleeve.

While conventional transmission lines of the aforementioned typenormally have sheath members with twelve inch O.D.s and wall thicknessesof 0.300 of an inch with the conductor that passes therethrough having a4 inch OD. and a 0.500 inch wall thickness and being formed inapproximately 40 foot lengths and to carry 230,000 to 450,000 volts, itis to be understood that the coupling construction, method and apparatusof this invention can be utilized to form coupling constructions ondevices other than high voltage transmission lines, as the couplingconstruction will still perform the sealing function previouslydescribed between the inner members and the outer coupling sleeve.However, for such a transmission line system, the coupling sleeve 19 andannular shims 24 can be formed of aluminum alloy 606l-T6 when the sheathmembers 22 and 23 are formed of aluminum-containing material.

Also, while the shims 24 previously described have both the upper andlower portions thereof welded by thesame weld material 25 to thecoupling member 19 and sheath members 22 and 23 with the weld material25 completely covering all of the exposed portions of the shims 24, itis to be understood that the shims 24 could be made relatively long soas to handle all pipe tolerances with one size shim 24 instead of two ormore which might be required if the shim 24 was formed in short lengthsas previously described and illustrated.

For example, reference is now made to FIG. 9 wherein another couplingconstruction of this invention is generally indicated by the referencenumeral A and parts thereof similar to the coupling construction 10previously described are indicated by like reference numerals followedby the reference letter A.

As illustrated in FIG. 9, a relatively long shim member 24A has itsangular face 29A for wedging against the respective angular surface 30Aon the coupling member 19A in the manner previously described exceptthat the tapering surface 29A terminates short of the other flat side 43of the shim member 24A so as to define a short cylindircal cylindrical44 thereof. However, the shim 24A is split in the same manner as theshim 24 previously described so that the same can be wedged between thecoupling member 19A and respective sheath member 23A so that theinternal cylindrical surface 45 of the shim member 24A will be forcedinto sealing engagement with the sheath member 23A while the angularsurface 29A thereof is forced into sealing engagement with the taperedsurface 30A on the coupling member 19A in the manner previouslydescribed and for the purpose previously described.

After each shim 24A has been wedged into the position illustrated inFIG. 9 for a particular coupling construction 10A, a first welding passis made to form the weld material 46 that welds the coupling sheath 19Ato the shim member 24A. Thereafter, a second welding pass is made toprovide the weld material 47 that secures the end surface 43 of the shimmember 24A to the sheath member 23A, as illustrated. Since the spacingbetween the coupling member 19A and sheath member 23A is completelysealed by the shim member 24A during the welding passes 46 and 47, nocontamination can take place for the reasons previously set forth.

Thus, it can be seen that the longer shim 24A of this invention willreadily permit the same joint areas for the coupling members and sheathmembers regardless of pipe tolerances so that the longer shim 24A can beutilized w6th substantially all of the pipe tolerances encounteredbecause the maximum stick out length of the shim 24A can varyconsiderably with different pipe tolerances.

Therefore, while a present preferred embodiment of the invention hasbeen illustrated and described, it will be recognized that the inventionmay be otherwise variously embodied and practiced within the scope ofthe following claims.

What is claimed is:

1. In combination, a pair of members respectively having ends disposedadjacent each other, a coupling sleeve having opposed ends and beingdisposed in telescoping relation about said adjacent ends of saidmembers, a pair of annular metallic shims respectively deformed intosubstantially sealing engagement with and between a respective memberend and said sleeve to substantially close the spacing between saidsleeve and said respective member end, each of said shims being in theform of a wedge when viewed in cross section having one annular angledsurface disposed in wedged relation against an inside surface of itsassociated sleeve end and having another surface disposed in wedgedrelation against an associated member, and weld means securing saiddeformed metallic shims to said respective member ends and to saidsleeve.

2. A combination as set forth in claim 1 wherein said members compriseelectrical sheaths of cylindrical configuration and said ends thereofare disposed in spaced and aligned relation; an electrical conductorpassing through said aligned sheaths, and spacers disposed between saidconductor and said sheaths to hold said conductor in spaced relationfrom said sheaths.

3. A combination as set forth in claim 1 wherein each sleeve end has anannular beveled surface comprising its inside surface, each shim havingits annular angled surface disposed in said wedged relation with acooperating beveled surface of said sleeve.

4. A combination as set forth in claim 1 wherein each shim has a splittherein to facilitate the deforming thereof.

5. In combination, a pair of members respectively having ends disposedadjacent each other, a coupling sleeve having opposed ends and beingdisposed in telescoping relation about said adjacent ends of saidmembers, a pair of annular shims with each shim being in the form of awedge when viewed in cross section, said shims being respectivelydeformed into substantially sealing wedged engagement with and between arespective member end and said sleeve to substantially close the spacingbetween said sleeve and said respective member end, and means securingsaid deformed shims to said respective member ends and to said sleeve,said means securing said deformed shims to said respective member endsand said sleeve comprises annular weld material extending from each endof said sleeve against an associated shim and onto an associated memberend.

6. In combination, a pair of members respectively having ends disposedadjacent each other, a coupling sleeve having opposed ends and beingdisposed in telescoping relation about said adjacent ends of saidmembers, a pair of annular shims with each shim being in the form of awedge when viewed in cross section, said shims being respectivelydeformed into substantially sealing engagement with and between arespective member end and said sleeve to substantially close the spacingbetween said sleeve and said respective member end, and means securingsaid deformed shims to said respective member ends and to said sleeve,said means securing said deformed shims to said respective member endsand said sleeve comprises a first and an axially spaced second annularwelds at each end of said sleeve, each of said first annular weldsextending from an associated end of said sleeve against an associatedshim and each of said second annular welds extending from an associatedmember end and against an associated shim so that each shim is engagedby two annular welds.

1. In combination, a pair of members respectively having ends disposedadjacent each other, a coupling sleeve having opposed ends and beingdisposed in telescoping relation about said adjacent ends of saidmembers, a pair of annular metallic shims respectively deformed intosubstantially sealing engagement with and between a respective memberend and said sleeve to substantially close the spacing between saidsleeve and said respective member end, each of said shims being in theform of a wedge when viewed in cross section having one annular angledsurface disposed in wedged relation against an inside surface of itsassociated sleeve end and having another surface disposed in wedgedrelation against an associated member, and weld means securing saiddeformed metallic shims to said respective member ends and to saidsleeve.
 2. A combination as set forth in claim 1 wherein said memberscomprise electrical sheaths of cylindrical configuration and said endsthereof are disposed in spaced and aligned relation; an electricalconductor passing through said aligned sheaths, and spacers disposedbetween said conductor and said sheaths to hold said conductor in spacedrelation from said sheaths.
 3. A combination as set forth in claim 1wherein each sleeve end has an annular beveled surface comprising itsinside surface, each shim having its annular angled surface disposed insaid wedged relation with a cooperating beveled surface of said sleeve.4. A combination as set forth in claim 1 wherein each shim has a splittherein to facilitate the deforming thereof.
 5. In combination, a pairof members respectively having ends disposed adjacent each other, acoupling sleeve having opposed ends and being disposed in telescopingrelation about said adjacent ends of said members, a pair of annularshims with each shim being in the form of a wedge when viewed in crosssection, said shims being respectively deformed into substantiallysealing wedged engagement with and between a respective member end andsaid sleeve to substantially close the spacing between said sleeve andsaid respective member end, and means securing said deformed shims tosaid respective member ends And to said sleeve, said means securing saiddeformed shims to said respective member ends and said sleeve comprisesannular weld material extending from each end of said sleeve against anassociated shim and onto an associated member end.
 6. In combination, apair of members respectively having ends disposed adjacent each other, acoupling sleeve having opposed ends and being disposed in telescopingrelation about said adjacent ends of said members, a pair of annularshims with each shim being in the form of a wedge when viewed in crosssection, said shims being respectively deformed into substantiallysealing engagement with and between a respective member end and saidsleeve to substantially close the spacing between said sleeve and saidrespective member end, and means securing said deformed shims to saidrespective member ends and to said sleeve, said means securing saiddeformed shims to said respective member ends and said sleeve comprisesa first and an axially spaced second annular welds at each end of saidsleeve, each of said first annular welds extending from an associatedend of said sleeve against an associated shim and each of said secondannular welds extending from an associated member end and against anassociated shim so that each shim is engaged by two annular welds.